Note: Descriptions are shown in the official language in which they were submitted.
4798 WO 1/9
A method and device for shaping structural parts
The invention relates to a method for shaping structural parts, especially
such for use in
aviation and space travel. The structural parts comprise a plate-shaped base
body and ribs
which are longitudinally extended, are approximately parallel to one another,
are joined
integrally to the base body, and protrude from the base body in orthogonal
manner, with
the shaping occurring by means of particles of blasting shot which strikes the
surface areas
of the structural part at a high velocity and produce a plastic material
shaping.
Especially in aeronautical and aerospace engineering so-called structural
parts or integral
parts are used which comprise ribs extending parallel with respect to each
other (mostly on
one side, but in certain circumstances also on both sides), while the side
that is not
provided with ribs is plane. If ribs are present both in the longitudinal
direction as well as
the transversal direction of the component which extend approximately
perpendicular with
respect to one another, the component is provided with a cassette structure.
In order to
curve such components it is necessary to apply complex processes because the
ribs,
especially when they extend parallel to the direction of curvature, offer
considerable
resistance against shaping.
Shaping methods of the kind mentioned above have long been used in
aeronautical and
aerospace engineering for curving large-surface components such as airfoils or
fuselage
shells. Blasting shot with a particle diameter of up to 2 to 4 mm is used in
the shaping of
structural parts. Whereas the blasting shot is applied with the help of
spinner gates for the
large-surface machining of components, hand blasting units are used for
locally limited
shaping. Said hand blasting units are also used for curving ribs. In order to
enable the
purposeful shaping of ribs that are usually flat on the basis of the blasting
geometry and
blasting diameter, the ribs are partly covered with a mask so that the desired
elongation
gradient is achieved in the rib zones to be shaped. Rubber or another impact-
absorbent
material is used for covering the surface sections of the ribs that are not to
be blasted. The
coverage of the ribs is cumbersome, especially when several masks need to be
produced.
As an alternative to the aforementioned shot blasting method, the so-called
clamping
method (Eckhold method) is known from the state of the art. In this method
clamps grasp
the rib with a kind of grasp with two spaced clamping jaws at two adjacent
places. As a
result of a short movement of the two clamping jaws away from each other or
towards each
other the rib is either locally extended or swaged. As a result of a repeated
application
along the longitudinal extension of the rib it is possible to produce convex
or concave
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curvatures. The curvature can be influenced by the stroke of the clamp and the
number of
repetitions of said applications.
Even if such clamping methods can be automated, it is still disadvantageous
due to the low
extensions per stroke of the clamping jaws which result in a lengthy shaping
process.
Despite the principally possible automation, the performing of the clamping
method
requires much experience by the operator, especially due to the danger of
buckling and the
spring-back behavior of the ribs.
Generally known are further so-called age creep forming methods for structural
parts. The
component is produced in a plane shape in this case by metal cutting,
especially milling.
Then the component is placed in a mould which has the external shape of the
finished part.
This shaping process usually takes several hours. A further disadvantage is
that special
moulds need to be produced for each geometry. It is further necessary to
determine the
parameters, temperature, pressure and time for each part separately.
Furthermore, the
application of the age creep forming method is excluded for materials which
are not
suitable for the thermal treatment conducted thereby. A further difficulty is
overextending
the part in the mould by a certain amount in order to compensate the spring-
back after the
removal of the component from the mould in order to ensure the precise desired
geometry
of the part.
The state of the art also includes the shot peen forming method as known from
the US Pat.
No. 4,329,862 for shot peen forming of plate-like parts, especially airfoil
structures. It is
not provided in this connection that the airfoil parts to be processed with
the blasting shot
are reinforced by ribs. The said US patent specification merely teaches that
the part is
stretched in a first step by blasting with blasting shot on either side and to
curve it into
another direction by blasting it with blasting shot on merely one side.
Finally, a method applied in practice for shaping structural parts consists of
milling the
same from solid material with the help of modern CNC milling machines. Apart
from the
considerable material input, this is merely possible for structures that are
curved to an only
very low extent. The costs incurred for raw material to be provided with a
large thickness
are considerable. That is why this method can be used in an economically
viable manner
only in a very few limited cases, especially where large-surface components
are concerned.
Moreover, there are strong back-spring effects in the finished part that are
the result of the
metal cutting process and impair its dimensional stability.
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The object of the invention is to provide a method for shaping structural
parts with which a
large number of geometries can be realized in a reliable and cost-effective
manner in the
finished parts.
Based on the shaping methods of the kind mentioned above, this object is
achieved in
accordance with the invention in such a way that opposite surface areas of the
ribs, with
said surface areas being located on opposite longitudinal sides of each rib,
are
simultaneously subjected to the action of particles of the blasting shot.
Since the processed surface regions are situated directly opposite each other,
any warping
or distortion of the rib in the direction transversally to its longitudinal
direction is securely
prevented. Such a warping is likely in cases when the rib (as in the hand
blasting method
according to the state of the art) is charged merely on one side with blasting
shot. The
effectiveness of every single particle hit is increased on the other hand by
blasting shot that
impinges simultaneously from both sides onto the rib surface. The energy
losses by elastic
material deformations are minimized in the method in accordance with the
invention.
Depending on the height of the rib (relating to the base body) at which the
application with
blasting shot on either side occurs according to the method in accordance with
the
invention, it is thus possible to achieve both convex as well as concave
curvatures of the
structural part thus treated. The size of the radius of curvature is
influenced by the size and
speed of the particles of the blasting shot as well as the duration of the
blasting treatment.
A particular advantage of the method in accordance with the invention is that
the shaping
of structural parts can occur exclusively by blasting the ribs, so that an
additional treatment
of the base body can be omitted. An automation of the proposed process is also
possible,
especially when the geometry of the treated structural part is measured on-
line and is
included in a process-control strategy for controlling the process.
According to a modification of the method in accordance with the invention, it
is possible
to blast with particles of the blasting shot either a longitudinal strip of
the rib adjacent to
the rib base or a longitudinal strip of the rib adjacent to the rib head. The
width of the
longitudinal strip can correspond at most to the height of the rib.
In the first case as mentioned above, the longitudinal and/or transversal ribs
of the part are
extended in the base region by blasting with blasting shot. This leads to a
concave
curvature of the part, with the term concave relating to the side of the plate-
like base body
comprising the ribs.
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In the alternative cases a convex curvature of the part is achieved by an
extension of the
longitudinal and/or transversal ribs in the head zone, i.e. in the vicinity of
its face side
extending in the longitudinal direction.
If the method in accordance with the invention is applied in structural parts
with a cassette
structure, i.e. with crossing longitudinal and transversal ribs, it is
possible to produce both
single-axis as well as mufti-axis component curvatures and involutes. If the
longitudinal
ribs are extended in the base region and the transversal rigs are extended in
the head
region, a combination of concave and convex curvature of the component is
obtained, thus
leading to a saddle-like geometry. In parts which comprise merely longitudinal
or
transversal ribs, a saddle-like structure can be achieved in such a way that a
curvature
transversally to the longitudinal direction of the ribs is performed by a
blasting shot
treatment of the base body in the manner as known in accordance with the state
of the art
(on one side).
In a further development of the invention it is proposed that the particles of
the blasting
shot have a mean diameter of more than 4 mm. In this way it is possible to
reliably shape
even structural parts with thick-walled ribs. Large-size particles, especially
large-size balls
with a diameter of more than 4 mm, allow a penetration of the ribs up to a
large depth.
A further development of the method in accordance with the invention is that
the particles
of the blasting shot emerge from oppositely situated, mutually facing nozzles
of a blasting
apparatus which is moved in the longitudinal direction and the upward
direction of the ribs.
This allows an automation in performing the method and the realization of a
large number
of geometries.
It is further advantageous to move the nozzles synchronously in the same
direction and
with the same speed. This ensures that even in the case of a continuing
displacement of the
place of treatment mutually opposite surface areas of the rib are processed.
An apparatus for shaping structural parts, especially such for use in aviation
and space
travel, with the structural parts comprising a plate-shaped base body and ribs
which are
longitudinally extended, are approximately parallel to one another, are joined
integrally to
the base body, and protrude from the base body in orthogonal manner, allows
blasting
surface zones of the structural part with particles of blasting shot impinging
at high speed,
as a result of which a plastic material deformation is produced, and is
characterized in
accordance with the invention by at least two nozzles for a directed delivery
of a particle
jet each, with the two particle jets being directed towards each other and the
nozzles having
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a larger distance from each other than the thickness of the rib. Preferably,
the nozzles can
be placed in intermediate spaces between adjacent ribs, making it possible to
direct the
particle jets under an angle of approx. 90° against the rib surface.
The shaping method as described above can be performed with such an apparatus
with
comparatively simple means. As a result of the fixed assignment of the two
nozzles and the
directions of delivery of the particle jets with respect to each other it is
always ensured that
mutually opposite surface areas of the ribs are processed. When the nozzles
can be placed
in intermediate spaces between adjacent ribs it is possible to provide a
perpendicular
direction of impingement of the particles on the surface areas to be
processed.
Finally, it is provided for in accordance with the invention that the nozzles
can be jointly
moved in the longitudinal and upward direction of the ribs, making it possible
to perform
shapings even in large components at a large variety of places in the ribs. It
is thus possible
to realize a large number of possible geometrical shapings on the part to be
shaped.
The method in accordance with the invention is now explained in closer detail
by reference
to an embodiment of an apparatus as shown in the drawing, wherein:
Fig. 1 shows an apparatus for shaping a structural part with two nozzles
directed against
each other;
Fig. 2a shows a perspective view of a section of a structural part;
Fig. 2b shows a side view of the component according to fig. 2a;
Fig. 2c shows a view as in fig. 2b, but after producing a convex curvature;
Figs. 3a to 3c show views as in figs. 2a to 2c, but for producing a cancave
curvature;
Fig. 4 shows the elongation distribution in a rib with a convex curvature;
Fig. 5 shows a view as in fig. 4, but with a concave curvature.
Fig. 1 shows merely two nozzles Ia and lb of an apparatus for shaping
structural parts,
with a slightly conical expanding jet 3a/36 of particle-like blasting shot
emerging from the
front side 2a and 2b of said nozzles. The particles of the blasting shot have
a spherical
shape and have a diameter of more than 4 mm (e.g. 6 mm). The supply of the
blasting shot
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6l9
to the nozzles la and lb as well as the further components of the blasting
apparatus are
generally known and therefore not shown in closer detail.
A structural part 4 is shaped from a metallic material with the partly shown
shaping
apparatus. Said structural part 4 consists of a plate-shaped base body 5,
which is only
shown in sections, and a plurality of ribs 6 which are connected integrally
with the base
body 5 and emerge therefrom in a right-angled manner. Only one of said ribs is
shown in a
sectional view for reasons of clarity of the illustration. The ribs 6 extend
parallel in such a
processed part and equidistant at such a distance from each other that the
nozzles .la and
lb, including the necessary feed device, can be positioned' in the
intermediate spaces
between adjacent ribs 6. The distance A between the nozzles 1 a and 1 b is
dimensioned in
such a way that the rib 6 which is to be treated and has a thickness D can be
interposed and
still offers enough space between the nozzles 1 a, 1 b and the rib surface in
order to ensure a
trouble-free discharge of the blasting shot.
Fig. 1 shows the case where the nozzles la/lb are aligned perpendicular to the
rib 6. It is
also possible to let the particle jet hit the rib surface in an inclined
manner from above
under an angle departing from 90°. The nozzles la/lb can then be
arranged in a plane
above the rib surface and can be moved.
The common longitudinal axis 7 of both nozzles lallb extends perpendicular to
the two
side surfaces 8a and 8b of the rib 6. This 'ensures that mutually opposite and
substantially
congruent surface areas are blasted by the jets 3a and 3b on the mutually
opposite side
surfaces 8a and 8b. In the case of equal intensity of the blasting shot, a
balance of power
thus prevails in the zone of the blasted rib sections which prevents any
buckling or one-
sided deflection of the rib 6.
Figs. 2a and 2b show a structural part 4 shown in sections and in a
perspective side view.
In said structural part ~. a longitudinal strip ~ extends starting from a rib
head parallel
to the longitudinal extension of rib 6 and is emphasized here. Said
longitudinal strip
whose width 11 is approx. 40% of the height 12 of the rib 6, is blasted with
blasting shot
with the help of nozzle 2b. Accordingly, an opposite longitudinal strip (which
is not
shown in the figure) with the same width 11 is also blasted with blasting
shot, namely by
using nozzle 2a. The nozzle arrangement as shown in fig. 1 can therefore be
moved in its
entirety in the longitudinal direction of the rib 6 (e.g. with constant
speed), i.e. without the
two nozzles 2al2b changing their position and alignment relatively.
i
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Fig. 2c shows which form the structural part 4 assumes after a blasting shot
treatment in
the zone of the longitudinal strips l0a and lOb. As a result of the material
extension
occurring in the zone of rib head 9, i.e. an elongation of the part in this
zone, both the rib 6
as well as the integrally connected base body 5 assume a convex curved shape.
Despite the
curved shape, the side surfaces 8a and 8b of the rib 6 are each situated
within one plane.
In addition to the curvature in the longitudinal direction of the rib 6, the
structural part 4
can be provided in addition with a curvature perpendicular to the longitudinal
extension of
the ribs 6 by a blasting shot treatment of either the lower side 13 or the
upper side 14 of the
base body 5. In this~way it is possible to produce saddle-like structures.
In the case of structural parts with cassette structure, i.e. crossing ribs in
the longitudinal
and transversal direction of the component, such a saddle-like structure can
be produced
merely by a blasting shot treatment of the ribs. Optionally, an additional
blasting shot
treatment of the base body is possible.
Figs. 3a to 3c show the case that with the help of a blasting shot treatment a
concave
curvature of the structural part 4 is to be produced. The longitudinal strip
l0a' is situated in
this case in the zone of the rib base 15 and is directly adjacent to the upper
side 14 of the
base body 5.
After performed blasting shot treatment of the mutually opposite longitudinal
strips l0a'
and lOb', the structural part 4 assumes the concave curved shape as shown in
fig. 3c. As a
result of the extension of the rib 6 in its base region, the material of the
plate-shaped base
body 5 is also extended. The width 11 of the longitudinal strips l0a' and lOb'
is again
approx. 40% of the height 12 of the structural part 4.
Figs. 4 and 5 finally show the extension distribution in the zone of the
longitudinal strips
l0a (at the rib head) and l0a' (at the rib base) which are to be treated with
blasting shot.
Whereas the elongation in the case as shown in fig. 4 increases linearly from
zero to a
maximum value starting from a lower limiting line 16 of the edge strip l0a up
to the rib
head 9, the elongation in the structural part 4 according to fig. 5 also grows
linearly starting
from an upper limiting line 17 of the longitudinal strip l0a up to the rib
base 15 at the
transition point into the base body 5 where there is a maximum value of the
elongation.
